Method for manufacturing tufted carpets



United States Patent 3,390,035 METHOD FOR MANUFACTURING TUFIED CARPETSSeymour Sands, Wilmington, Del., assignor to E. I. du

Pont de Nemours and Company, Wilmington, DeL, a corporation of DelawareNo Drawing. Continuation-impart of application Ser. No.

241,548, Dec. 3, 1962. This application May 12, 1966,

Ser. No. 549,461

3 Claims. (Cl. 156--72) ABSTRACT OF THE DISCLOSURE Tufted carpets arebacksized with a non-aqueous, solvent free polymeric material containinga copolyrner of ethylene and vinyl acetate by applying the polymericmaterial to the back side of the carpet as a hot melt.

This application is a continuation-in-part of U. S. application Ser. No.241,548, filed Dec. 3, 1962 now abandoned.

Background of the invention In preparing carpets for floor coverings andsimilar uses it has been the practice to apply adhesives as backsizes inthe form of a latex. The wet latex is spread onto the back side of thecarpet and is then heated to dry or cure it. Recently, in US. Patent3,142,611, polyethylene, nylon, acetal resins, polyvinyl chloride andpolypropylene have been disclose-d as suitable thermoplastic backinglayers for non-woven pile fabrics. The use of a latex which involvesdrying or curing is both time consuming and requires careful control inorder to prevent damage to the tufted structure. The use of theaforementioned thermoplastic materials also entails problems of controldue to their high viscosities at application temperatures.

Description of the invention It has been found that a tufted carpethaving outstanding physical and aesthetic properties is provided byapplying to the bottom surface of a tufted structure a layer of moltenthermoplastic adhesive material comprised of (1) about to 90% by weightof an ethylene copoly mer containing about 60% to 85% by weight ofethylene units and about 40% to by weight of vinyl acetate units, (2)about 90% to 10% by weight of a wax, and (3) optionally, 0 to about 80%of a thermoplastic resin other than the ethylene copolymer, thepercentages of the various ingredients being based on the total weightof the composition. As the molten adhesive is distributed uniforrnlyacross the back side of the carpet, it penetrates the base of the tufts.The adhesive layer is then cooled, and as it solidifies, the base ofeach loop or tuft is firmly anchored to the backing material.

The melting point of the adhesive composition should usually be about160 to 300 F., preferably about 180220 F.

The tufted carpets of this invention have a coating of polymericmaterial, generally 10 to 30 ounces per square yard, integrallylaminated or adhered to the back side thereof. A wide variety of textilematerials may be used in fabricating the carpet. The carpet backingmaterial which is stitched with the pile yarn can be any sheet materialadapted for use as the primary backing of a tufted carpet. Usefulprimary backing materials include woven jute fabric, woven cotton fabricand various known highstrength non-woven fabrics. Jute fabric iscommonly used for broadloom carpets and cotton fabric for scatter'rugsand bath sets. Jute fabric is ordinarily used in weights "of about 9, 10or 12 ounces per square yard, and cotton fabric in weights of about 3.5to 10 ounces per square yard.

A useful type of non-woven fabric for the primary backing material isone that contains, as the major fibrous component, continuous syntheticorganic filaments having a loopy configuration and separate and randomdisposi tion within the fabric, the majority of the loops being disposed substantially in the plane of the fabric, and the filaments beingbonded together at spaced points throughout the fabric. By using such anon-woven fabric backing, carpets are obtainable by the present methodhaving improved dimensional stability, resistance to mildew and insects,dyeability, and pile appearance (due to absence of exudation stains).These and other strong non-woven fabrics are available commercially inlarge quantities and highly uniform qualities.

The essential filaments of the above-mentioned continuous-filamentnon-woven fabric has a loopy configuration; that is, the average lengthof the individual filaments within any given circle greater than thediameter of that circle, preferably at least 1.2 times the diameter. Themajority of the loops are disposed substantially in the place of thefabric and are to be distinguished from the acute transverse loops whichresult from needle-punching. Filament loops have either an amplitude ofdeparture from a straight line of at least 0.6 inch associated with aradius of curvature of at least 0.2 inch, or a radius of curvature ofover 0.5 inch.

The essential filaments also have a separate'disposition within thefabric, which means that they are nonaggregated, non-roped, or free ofclusters of parallel filaments. In other words, substantially none ofthe filaments are in juxtaposition with each other over any substantialproportion of their length. They do, of course, often touch at pointswhere they cross.

The fabric filaments can be crimped or noncrimped. Noncrimped filamentsare usually preferred for economical reasons. However, acrimped-filament fabric is advantageous when a relatively supple ordrapable carpet is desired. In a filament crimp, the amplitude of thedeparture from a straight line is less than 3 times the radius ofcurvature, the latter always being less than 0.5 inch.

Crimp can be imparted to the filaments by known methods, for example, astaught by Hebeler in US. Patent 2,604,689, or by Kitson and Reese inBelgian Patent 566,145. The filaments can be crimped. either during orafter their formation into the fabric.

The major fibrous component of the fabric should be continuous filamentsof a fiber-forming synthetic organic polymer. Melt-spinnable polymersare preferred since they can be formed into the required non-wovenfabric in a single continuous operation. Particularly preferred aremelt-spinnable polymers which form filaments which can be charged bycorona discharge or other field charging means, or triboelectrically.Such polymers areexemplified by the following: polyesters, such aspoly(ethylene terephthalate) and poly(hexahydro-p-xylylene terephthal--hydrocarbons, such as polypropylene and polyethylene; polyurethanes;polycarbonates; and polyacetals.

Triboelectrically chargeable filaments become electrostatiscally chargedwhen they are in intimate rubbing contact with a suitable solid surface,such as a surface comprised of aluminum, brass or chromic oxide.

The nonwoven fabric of the loopy and separate continuous filaments canbe made by a process which comprises electrostatically charging arunning multifilament yarn, preferably a no-twist yarn, composed ofcontinuous synthetic organic filaments capable of holding anelectrostatic charge to a potential sufiicient to separate the filamentsfrom one another, followed by collecting the charged and separatedfilaments on a receiver maintained at a potential differing from that ofthe filaments. The receiver can be a plate, screen, belt or the like,and is preferably in linear and/or circular motion during filamentcollection so as to control fabric properties such as shape, uniformityand thickness.

A method which is preferred for its simplicity and efiiciency compriseselectrically charging freshly meltspun filaments and simultaneouslyorienting them and urging them towards the receiver by means of anaspirating jet. Enroute to the receiver, the filaments are convenientlytriboelectrically charged as they are passed in rubbing contact withguides or the throat of the aspirating jet having a suitable surface forproducing the desired charge, such as a surface of aluminum, brass orchromic oxide. The polarity of the induced charge is governed by therelation of composition of the filaments and the surface in rubbingcontact therewith as indicated in the triboelectric series ofmaterialssee, for example, V. E. Shashoua in Journal of Polymer Science,33, p. 65 (1958). Alternatively, the electrical charging can beaccomplished at similar locations by means of a field charging device.

Filaments of the non-woven fabric should be bonded together at spacedpoints (such as cross-over points) throughout the fabric. Such bondinggives the fabric strength and adapts it for carpet-backing utility.Spaced bonding of the filaments in the fabric can be accomplished byvarious methods, such as one or more of the following: (1) spraying,atomizing or otherwise discharging a binder onto the filaments as soonas they have been charged, for example, charged fibrils or other polymerparticles having a polarity opposite to that of the filaments; (2)dipping, spraying or otherwise applying binder particles or a dispersionor solution of binder to the fabric as formed or after its formation onthe receiver; (3) cospinning binder filaments along with the essentialfilaments, either from the same or an adjacent spinneret; (4) pressingand/or heating the as-formed fabric (this is a preferred method); (5)needle-punching the as-formed fabric, for example, as taught byLauterbach and Norton in US. Patent 2,908,064.

Preferred binders with which the filaments can be bonded together attheir cross-over points include synthetic organic polymeric materials.The following are representative of the more useful polymeric binders:(1) polyester copolymers, such as an 80/20 copolymer of ethyleneterephthalate and ethylene isophthalate, especially when used as afilamentary binder for poly(ethylene terephthalate) filaments; (2)polyamide copolymers, such as a 90/ copolymer of hexamethylene adipamideand caproamide, especially when used as a filamentary binder forpolyamide filaments; and (3) elastomeric acrylic copolymers, especiallywhen applied from a dispersion, such as a copolymer of about 94-99% byweight of a methyl, ethyl, propyl or butyl ester of acrylic ormethacrylic acid and 16% by weight of acrylic, methacrylic or itaconicacid, and preferably a terpolymer formed by copolymerizing about 80-90parts ethyl acrylate, 4-20 parts methyl acrylate or methyl methacrylateand 1-6 parts acrylic or methacrylic acid, as taught in Example A of US.Patent 2,757,106. These copolymers are also useful when reacted with anoxide, hydroxide or 4 basic salt of a polyvalent metal as described inthe cited patent.

The best amount of binder to employ usually falls within the range ofabout 350% by weight of bonded fabric, although more binder sometimesgives good results.

In addition to the essential continuous filaments the fabric can containa minor proportion of any other material known to be useful in fibroussheet structures, such as fibers of paper-making length and any of theknown staple fibers including crimped or uncrimped, organic andinorganic, natural and synthetic fibers.

A more detailed description of the bonded nonwoven fabrics describedabove which are useful in practicing this invention, as well as methodsof making them, is given by Guandique and Katz in Belgian Patent 608,644and by Kinney in Belgian Patent 608,646. The disclosures of these twopatent are incorporated herein by reference.

Methods known in the art of making tufted carpets are employed forstitching the primary backing material with yarn in such a manner as toform on the top (normally exposed) surface of the material a pilecomposed of numerous closely-spaced erect loops of yarn. The yarn at thebase of each loop extends through the primary backing and is visible onthe bottom surface of the resulting loop-stitched or tufted structure.

The yarn used in forming the pile can be made of any type of fiber knownto be useful for tufted carpets, for example, nylon, acrylics, wool,cotton and rayon.

A layer of the thermoplastic adhesive composition is applied in a moltencondition to the bottom surface of the tufted structure; thus, thebottom of the primary backing and the base portion of the loops of pileyarn present therein are coated with the molten adhesive.

It is usually best to apply the adhesive in an amount equal to about 10to 30 ounces per square yard of tufted material. The best amount toapply in a particular application will depend on such factors as desiredstrength of tuft bond, density of the adhesive composition being used,and the proportion and cost of film-forming components. Another factoris whether or not a secondary backing is to be applied.

Any method known in the art of applying coatings of molten thermoplasticadhesives can be employed for applying the adhesive layer, for example,by extrusion, heated doctor blade, or by passing the bottom surface ofthe tufted material in contact with the top surface of a rotating rollerpartially submerged in a tank of the molten adhesive. A doctor blade iscommonly used to control the thickness of adhesive on the roller.

The adhesive layer on the tufted material, after it has solidified bycooling, firmly bonds the base of each loop of yarn to the primarybacking material. When the carpet is also to comprise a secondarybacking, the cooling of the adhesive layer can be delayed until afterthe secondary backing is applied. Alternately, the cooled adhesive layercan be reactivated by heating at least the exposed surface of it to amolten state, applying the secondary backing and again cooling theadhesive layer. A third technique is to apply a second layer of moltenadhesive to the solidified first layer, apply the secondary backing, andcool. After the secondary backing is applied, regardless of technique,in contact with a layer of the molten adhesive which layer is thencooled, the secondary backing becomes a firmly bonded integral part ofthe carpet structure.

Useful secondary backing materials include the materials listed above asprimary backing materials as well as others known in the carpet-makingart, for example, those woven from paper-fiber cord.

The tuft-bonding adhesive composition contains about 10 to 90%,preferably about 20-55%, of an ethylene copolymer based on the weight ofthe film-forming components. The ethylene copolymer contains about -85%,

preferably about -75%, of ethylene units and about 40-15%, preferablyabout 35 25%, of vinyl acetate units based on the weight of thecopolymer. The procedures described in US. Patents 2,200,429 and2,703,794 are useful for preparing the ethylene/vinyl acetate copolymer.The ethylene copolymer can also contain about 0.001 to 3% of a comonomersuch as acrylic acid, methacrylic acid, itaconic acid, acrylamide, betadimethylaminoethyl methacrylate, beta hydroxyethyl acrylate, diallylmaleate, diallyl phthalate, diallyl ether or ethylene glycoldimethacrylate.

An ethylene copolymer having an inherent viscosity of about 0.45 to 1.50is usually preferred and one having an inherent viscosity, which variesdirectly with the molecular weight, is measured from a 0.25% solution ofthe copolymer in toluene at 86 F;

As the second component, the adhesive composition contains about 90 topreferably about 50 to 10% (based on the weight of the film-formingcomponents) of a wax. A wax is selected having a melting point such thatthe adhesive composition has a suitable melting point for the intendedapplication. Preferred waxes have a melting point of about 120-220 F.and include Fisher-Tropsch waxes and the hydrocarbon waxes obtained bythe distillation of petroleum (petroleum waxes), such as paraffin waxesand microcrystalline waxes. Candelilla and carnauba are also usefulwaxes, especially when they make up a minor proportion of the waxcomponent.

As an optional film-forming component, the adhesive composition cancontain up to about 80%, preferably about to 64% (based on the weight offilm-forming components), of a thermoplastic resin other than saidethylene copolymer. This resin should have a melting point such that theadhesive composition has a suitable melting point. The useful resinsinclude the polyterpenesresins obtained by distillation of conifers. Therosin family of resins (rosin and solid rosin derivatives) constitute aparticularly useful class of resins, including such derivatives asesters of rosin and glycerol, esters of rosin and pentaerythritol,hydrogenated rosin, and esters of hydrogenated rosin and glycerol orpentaerythritol. Also useful are various coumaroneindene resins,permanently fusible phenolic resins, and petroleum hydrocarbon resinsformed from dienes and reactive olefins via the deep cracking ofpetroleum. A typical useful petroleum hydrocarbon resin (e.g., Piccopale1005 from Pennsylvania Industrial Chemical Corporation) has a softeningpoint (B.R.) of about 212 F., a specific gravity at 77 F. of 0.970 to0.975, a refractive index at 68 F. of 1.5ll6, an acid number of lessthan one, an iodine value of 120 (WIJ S), a bromine number of 7.3 and amolecular weight of about 1100.

Another optional but sometimes preferred ingredient of the adhesivecomposition is a filler in the form of a finely divided material thatdoes not melt or decompose at the temperature of the molten adhesive.The best amount of a particular filler to add will depend on suchfactors as the influence that the filler has on viscosity of the moltenadhesive and the required strength of tuft bond. With such preferredfillers as barium sulfate, calcium carbonate, talc, clay and silica, upto about 50% filler can usually be added (based on the total weight ofadhesive) without undue reduction of bond strength or increase inviscosity, the preferred amount in most cases being about -35%.

A stabilizer can be added to enhance the pot-life of the moltenadhesive. Typical useful stabilizers or antioxidants for the adhesivecomposition are the 2,4,6-trialkylated monohydroxy phenols, e.g.,2,4,6-tri-tertiarybutyl phenol and 2,6-di-tertiary-butyl-4-methylphenol, which are available from Shell Chemical under the trademarkIonol; 4,4-thio-bis(6-tertiary butyl m-cresol) available from Monsantoas Santowhite crystals; butylated hydroxy anisole and butylated hydroxytoluene. Effective proportions of stabilizer ordinarily are in the rangeof from about 25 parts per million to about 0.5 part per 100 parts byweight of the adhesive composition, preferably about 0.1 to 0.4 part per100.

Other additives, for example, pigments and plasticizers, can also beadded to the adhesive.

To illustrate the preparation of the adhesive composition, a wax, anantioxidant and a polyterpene resin can be melted and mixed at about 250F., then the ethylene copolymer added slowly with stirring untilthoroughly dispersed. Or a sigma blade mixer can be used to blend theethylene copolymer with about an equal weight of wax and/or polytcrpeneresin at about 250 F. until a smooth, uniform molten mixture isobtained, then the remaining wax and/or polyterpene resin and any fillerto be added is blended in. The molten mixture can be pumped directly toa carpet coating apparatus or cast into slabs for subsequent remeltingprior to use in the method of this invention. I

The novel method of this invention permits tufted carpets of excellentquality to be manufactured with surprising speed, from 30 to 60 f.p.m.In contrast with prior art methods which employ rubber latex tuftadhesives, this method has the following advantages:

(1) Instead of requiring a lengthy drying and curing period to set theadhesive, it is set simply by chilling it; thi takes only a few minutes.

(2) Since the cooling rolls or other chilling means take up much lessplant space than the long drying and curing ovens needed in a latextuft-adhesive system, greater yardage of product can be made in a plantof any given size.

(3) Since the carpet structure is not exposed to an elevated temperaturefor an extended period of time, as it is in a latex system, the dangerof damaging heat-sensitive pile yarns or coloring agents issubstantially eliminated. The vapors liberated in the ovens of a latexsystem are also a source of yarn and colorant damage.

(4) If defects are noticed in the secondary backing after it is bondedto the carpet structure, the defective backing is readily removed andreplaced following heating the adhesive layer to its melting point; in alatex system, such a salvage operation is impossible.

(5) Each step in this process can be watched closely and if somethinggoes wrong it can be corrected at once; in a latex system, since a largeyardage of material is hidden from view in the drying and curing ovens,trouble is sometimes not detected until after there is a seriousfinancial loss.

(6) It is common for a latex adhesive to give the finished carpet anundesirable odor. The adhesive used in the present method is welladapted for odorless formulation.

(7) When using certain high-strength nonwoven fabric backings, thepresent method is capable of giving superior adhesive of loops to thenonwoven material and adhesion of nonwoven secondary backing to thecarpet compared with latex and other prior art systems. And the methoddoes not require processing temperature-time cycles harmful to nonwovenbackings made of polyethylene and the like.

(8) Superior adhesion of the pile loops is also obtainable when usingconventional jute backings.

The product of this novel method is useful wherever carpets are used,for example, on automobile floors and on floors and stairways in homes,restaurants, hotels, office buildings, and in passenger sections ofships, trains and airplanes.

The examples which follow are given for the purpose of illustrating theinvention. All quantities shown are on a weight basis unless otherwiseindicated.

Example 1 A tufted broadloom carpet is manufactured by first stitching aconventional woven jute fabric primary backing material with a tuftedcarpet grade of nylon yarn to form on the top surface of the jute fabrica pile of closely spaced erect loops of the yarn. The jute fabricbacking has a weight of 12 ounces per square yard, a width of 15 feetand a length of feet. In the stitching (tufting) operation, the backingmaterial is advanced by means of conventional drive rolls, the tuftingis done at a Ethylene copolymer 14.0 Wax, synthetic 17.0 Rosin, Grade WG30.6 Dimerized rosin (Hercules Poly-pale Resin) 8.2 Calcium carbonatefiller 30.0

Stabilizer (Ionol G-685: 2,4,6-tritertiary-butyl phenol) 0.2

The ethylene copolymer is a 67:33 copolymer of ethylene and vinylacetate having an inherent viscosity of 0.78 (0.25% in toluene at 86F.), a melt index of 26 (ASTM- D-1238-57T), and a softening point of 243F. (ring and ball).

The synthetic wax (Paraflinf RG from Moore and Munger Company) has amelting point of 215 F.; it is a Fisher-Tropsch Wax.

As the tufted material moves through the coating apparatus, the bottomside of the material passes across the top surface of an applicatorroll, the latter being mounted for rotation on its axis and partiallysubmerged in a tank of the molten adhesive which is kept at 275 F. Adoctor blade mounted near the applicator roll controls the thickness ofthe adhesive layer on the roll so that the desired 20 ounces per squareyard is applied to the carpet material.

While the adhesive coating is still in a molten state, the coatedmaterial is continuously superposed onto a secondary backing material sothat the adhesive coated side is in contact with the secondary backing.The secondary backing material is a woven jute fabric weighing aboutounces per square yard. Next, the resulting composite material is passedimmediately between a pair of nip rolls where the material is subjectedto moderate pressure and then around a series of chilled rolls tosolidify the adhesive layer.

The product, a high quality double-backed broadloom carpet, is wound upon a storage roll. The primary and secondary backing materials arefirmly bonded to each other, and the base of each loop in the pile isfirmly bonded to the primary backing. A pull of 13.8 pounds (on theaverage) is required to pull one of the pile loops loose from theprimary backing.

The product is useful as a carpet for covering the floors and stairs ofhomes and other buildings where carpets are normally used.

Example 2 A tufted carpet is produced by repeating Example 1 except thesecondary backing material is a nonwoven fabric weighing 3.3 ounces persquare yard. The fabric is composed of poly(ethylene terephthalate)continuous filaments having a loopy configuration, about 50 crimps perinch, and separate and random disposition within the fabric, thefilaments being bonded together at spaced points throughout the fabricwith cospun filaments of an 80/20 copolymer of ethylene terephthalateand ethylene isophthalate. The majority of the loops are substantiallyin the plane of the fabric. The weight ratio of the poly- (et-hyleneterephthalate) filaments to the copolymer binder filaments in the fabricis 91:9.

The nonwoven fabric is prepared as follows. Using an apparatus similarto that described in Example 2 of Belgian Patent 608,646, poly(ethyleneterephthalate) having a relative viscosity of 34 is melt-spun intofilaments from a 68-hole spinneret (7 mil hole diameter) while the 80/20ethylene terephthalate/isopht-halate copolymer is cospun into filamentsfrom an adjacent 34-hole spinneret. Nine grams of copolymer filamentsare spun for each 91 grams of the former. The freshly spun filaments arepassed in rubbing contact with chromic oxide guide bars to give them aninduced electrical charge. An aspirating air jet operating with 50p.s.i.g. pressure is employed to attenuate and quench the filaments,advance them to an aluminum plate receiver and lay them down on thereceiver in separate and random fashion in the form of a looselyconstructed nonwoven fabric or batt. The receiver is moved sufficientlyto yield a batt of uniform thickness.

Next, the batt is placed between two sheets of paper in a press andconsolidated into a denser and stronger nonwoven fabric under a pressureof 150 p.s.i. while heated to 60 C. The consolidated fabric is removedfrom between the paper sheets, placed in the press between two pieces of60 mesh wire screen, and embossed under a pressure of 150 p.s.i. whileheated at 210 C. The latter operation completes the crimping and thebonding of the filaments. The fabric can be dyed as desired, forexample, with a red dye. Carpet properties and utility are similar tothose of the Example 1 product.

Example 3 A tufted carpet having properties and utility similar to theproduct of Example 1 is produced by repeating Example 2 except thenonwoven fabric secondary backing material is made of polypropylenefilaments. The nonwoven fabric is made by the procedure described inExample 3 of Belgian Patent 608,646. The molten adhesive coating is at atemperature of about 264 F, when the adhesive-coated tufted material issuperposed onto the secondary backing material (just below the softeningpoint of the nonwoven).

A similarly useful carpet can be made by'replacing the polypropylenefilaments in Example 3 with polyethylene filaments.

Example 4 A tufted carpet is produced by repeating Example 3 example 3except the polypropylene nonwoven fabric described in that example isused as the primary backing material as well as the secondary backingmaterial. When the product of this example is installed as awall-to-wall carpet in a home living-room, it is resistant to ripplingand buckling on wide fluctuations in relative humidity.

Example 5 A tufted carpet is produced by repeating Example 1 except themolten adhesive composition has the following formula:

Percent by weight The molten adhesive has a viscosity of about 3000centipoises at 335 F. At 77 F., a sample of the solid, rubbery adhesivecomposition having a cross-sectional area of A; square inch has a600-800% elongation at break and a tensile modulus of about 320 p.s.i.

Example 6 A tufted carpet is produced by repeating Example 3 except forthe following differences: The tufted primary backing is coated with 16ounces per square yard of a molten adhesive composition having thefollowing formula:

Percent by weight Ethylene copolymer 31.0

Microcrystalline petroleum wax, MP. 190'- 195 F 30.0 Rosin 38.6Stabilizer-same as in Example 1 0.4

The ethylene copolymer is a 72:28 copolymer of ethylene and vinylacetate having an inherent viscosity of 0.85, a melt index of 15 and asoftening point of 252 F. (all measured as indicated in Example 1). Thenonwoven fabric secondary backing material is coated with 6 ounces persquare yard of the molten adhesive at a temperature of 250 F. justbefore the adhesive-coated tufted material is superposed thereon, givingthe composite adhesive layer a total weight of 22 ounces per squareyard.

In the product of this example, a pull of 24 pounds is required (on theaverage) to pull one of the pile loops loose from the primary backing.

Example 7 A tufted carpet is produced by repeating Example 1 except thatthe tufting fiber is polypropylene, and 16 ounces of the followingmolten adhesive is applied to the back side of the carpet at atemperature of 310 F.

Stabilizer (butyl hydroxylated toluene) 0.2

The ethylene copolymer contains about 27-29% by weight vinyl acetate,has a melt index of 12-48; and a softening point of 280 F. (propertiesmeasured as in Example 1). The rosin component is Piccovar L70,Pennsylvania Industrial Chemical Crp.s alkyl aromatic resin having asoftening point of 70 C. The carpet was moved past the coating stationat a rate of 30 feet per minute.

The resulting carpet exhibited excellent physical and aestheticproperties.

Since many different embodiments of this invention may be made withoutdeparting from the spirit and scope thereof, it is to be understood thatthe invention is not limited by the specific illustrations except to theextent defined in the following claims.

I claim:

1. A process for backsizing a tufted carpet having a primary textilebacking and non-Woven tufts of synthetic fibers protruding therefromwhich comprises heating a non-aqueous solvent free polymeric backsizingcomposition to a temperature of about 160 F. to 300 F., said temperaturebeing below the melting points of said textile backing and saidsynthetic fibers and substantially above the melting point of saidcomposition, applying a uniform coating in an amount from about 1.0 to30 ounces per square yard of said carpet of said composition in a moltenstate to the back side of said carpet at a coating station while movingsaid carpet past said station at a speed of from about 30 to feet perminute, and thereafter solidifying said coating by cooling it below itsmelting point, said backsizing composition consisting essentially offrom about 10% to 90% by weight of a copolymer of ethylene and vinylacetate containing from about 60% to by weight of ethylene and fromabout 40% to 15% by weight of vinyl acetate, from about to 10% by weightof wax, and 0 to about 80 by weight of a thermoplastic resin selectedfrom the group consisting of rosin and solid rosin derivatives,coumaroneindene resins, permanently fusible phenolic resins andpetroleum hydrocarbon resins.

2 The process of claim 1 wherein said polymeric composition has :amelting point of about F. to 220 F., said composition consistingessentially of about 20% to 55% of the eythylene copolymer, about 50% to10% of wax, and about 20% to 64% by weight of said thermoplastic resinand from 25% to 35% by weight of an inert filler.

3. The process of claim 1 wherein a secondary carpet backing is appliedto the back side of said carpet prior to the cooling step.

References Cited UNITED STATES PATENTS 2,675,337 4/1954 Walker et al.161-67 3,025,167 3/1962 Butler. 3,043,553 8/1962 Moss 161251 3,036,9425/1962 Squier.

ROBERT F. BURNETT, Pnimary Examiner.

ALEXANDER WYMAN, Examiner.

R. A. FLORES, L. M. CARLIN, Assistant Examiners.

